Mud saver mat for rig floors and other areas

ABSTRACT

Mats, pipe stands, and/or other structures, and methods for receiving fluid drained from one or more oilfield tubulars are described. Usable mats can include a base member at least partially impermeable to fluid from the oilfield tubulars, a first plurality of support arms secured to the top surface of the base member, and a second plurality of support arms intersecting the first plurality of support arms. The intersection between the pluralities of support arms defines openings through which fluid from oilfield tubulars supported on top of the support members or within the openings can drain, such that fluid from the tubulars does not spread on a rig floor or other surface beneath the base member. The base member and/or support arms are provided with a height and/or thickness adapted to support the weight of one or more oilfield tubulars placed thereon.

FIELD

The present invention relates, generally, to mats, pipe stands, and/orsimilar structural containers and methods for receiving fluid from oneor more oilfield tubulars to prevent the fluid from collecting and/orspreading on a rig floor.

BACKGROUND

While drilling and/or performing other operations within a well,drilling mud and other viscous fluids are flowed through variousoilfield tubulars, which can include drill pipe, casing, and similarconduits usable within the well. After use, the disassembled oilfieldtubulars can retain drilling mud and other thick and/or viscous fluidsthat adhere to the inner surface. Conventionally, these disassembledtubulars are placed in an unused area of a rig floor and allowed toslowly drain over time. This process causes drilling mud or other fluidscontained within the tubulars to spill on to the rig floor, and oftenspread undesirably to areas of the rig floor that will be trafficked,creating a safety hazard. The draining process also requires significantremedial and/or clean up operations once the tubulars have drained, suchas by washing the area of the rig floor used to store the disassembledtubulars. Furthermore, conventional draining processes fail to reclaimused drilling mud from the interior of the disassembled tubulars forreuse.

A need exists for methods and mats or other similar apparatuses thatsupport the weight of one or more oilfield tubulars during the drainingprocess while collecting the fluid that drains therefrom, therebypreventing the drained fluid from being spread on the rig floor toprevent accidents from slipping and falling, or similar events, whileenabling the drained fluid to be reclaimed, or alternatively, discardedwhen desired.

The present invention addresses these needs.

BRIEF DESCRIPTION OF THE DRAWINGS

In the detailed description of the embodiments of the inventionpresented below, reference is made to the accompanying drawings, inwhich:

FIG. 1 depicts an isometric view of an embodiment of a mat or similarstructural container or mat usable within the scope of the presentdisclosure.

FIG. 2A depicts a top view of the mat of FIG. 1.

FIG. 2B depicts a side view of the mat of FIG. 1.

FIG. 3 depicts an isometric view of an alternate embodiment of a mat orsimilar structural container usable within the scope of the presentdisclosure.

FIG. 4A depicts a top view of the mat of FIG. 3.

FIG. 4B depicts a side view of the mat of FIG. 3.

The depicted embodiments of the invention are described below withreference to the listed Figures.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Before explaining the disclosed embodiments of the invention in detail,it is to be understood that the present invention is not limited to theparticular embodiments depicted or described, and that the invention canbe practiced or carried out in various ways.

The present invention relates, generally, to mats, pipe stands, and/orstructural containers, and methods for receiving fluid from at least oneoilfield tubular and preventing the fluid from spreading on or otherwiseundesirably contacting a rig floor. In an embodiment of the invention, amat can be provided, having a base member at least partially impermeableto fluid from one or more oilfield tubulars, a first plurality ofsupport members or arms secured to the top surface of the base memberalong one side, with a second side spaced from the first, and a secondplurality of support members or arms intersecting the first plurality ofsupport members or arms. The first and second pluralities of supportmembers or arms intersect one another, such as in a perpendicularorientation, to define openings for permitting movement of fluid fromthe oilfield tubulars therethrough, to contact the base member below.Each of the support members or arms and/or the base member can beprovided with a height and/or other dimensions adapted to support theweight of one or more oilfield tubulars placed thereon. In an embodimentof the invention, an end of one or more of the oilfield tubulars can beplaced within an opening of the mat to provide lateral support to thetubulars during the draining process.

In use, one or more oilfield tubulars are placed on top of the mat, orwithin one of the openings, as described above, in a generally verticalorientation or other selected position, such that fluid from theoilfield tubulars will flow through the openings within the mat tocontact the base member. The fluid is thereby prevented from contactingand/or spreading undesirably on the rig floor and can be easilycollected and/or cleaned from the mat.

Referring now to FIG. 1, an embodiment of a mat (10) usable within thescope of the present disclosure is shown. The mat (10) is shown having abase member (12), which is depicted as a continuous, flat, generallyrectangular segment of at least partially liquid-impermeable materialable to be positioned over a section of a rig floor within which one ormore oilfield tubulars can be retained while fluid is drained therefrom.In selected embodiments of the invention, the mat (10) can be placed ina depression or similar recessed area of the rig floor to enable the topsurface of the mat (10) to be generally flush with the rig floor. Whilethe shape and dimensions of the base member (12) can vary depending onthe number and type of oilfield tubulars to be retained thereon, and thecorresponding shape and dimensions of other portions of the mat (10), inan embodiment of the invention, the base member (12) can have a lengthof approximately 22 inches, a width of approximately 13 inches, and athickness of approximately one inch. Additionally, while the base member(12) can be formed from any generally rigid, durable material able towithstand the weight of one or more oilfield tubulars, exposure todrilling mud and other fluids, and exposure to ambient weather or otherenvironmental conditions, in various embodiments of the invention, thebase member (12) can be formed from steel, one or more other metals oralloys, plastic, rubber, one or more composites, one or more polymers,or combinations thereof. In a further embodiment of the invention, thebase member (12) can be formed from a plastic material similar to thatused within thread protectors and/or similar plugs or caps for oilfieldtubulars, readily able to withstand the structural weight of oilfieldtubulars. In selected embodiments of the invention, the base member (12)and/or other portions of the mat can include a generally flexiblematerial.

A first plurality of support arms (14) are shown secured to the topsurface of the base member (12). The means by which the first supportarms (14) are secured to the base member (12) can include any manner ofbolts, screws, rivets, clamps, or other types of fasteners, adhesives,or similar types of securing known in the art. Additionally, in anembodiment of the invention, the base surface (12) can be provided withone or more grooves or notches sized to receive the first support arms(14). While the number, spacing, orientation, shape, and dimensions ofeach of the first support arms (14) can vary depending on the shape anddimensions of the base member (12) and the number and type of oilfieldtubulars to be retained thereon, FIG. 1 depicts seven, generallyrectangular first support arms (14), evenly spaced across the length ofthe base member (12), in a generally parallel relationship to a firstside of the base member (12) and to one another. Though the size andshape of the first support arms (14) can vary, as described previously,in an embodiment of the invention, each of the first support arms (14)can have a length equal to the width of the base member (12), a width ofapproximately one inch, and a height of approximately four inches.

FIG. 1 also depicts a second plurality of support arms (16) secured tothe first plurality of support members (14). Specifically, FIG. 1 showsfive, generally rectangular second support arms (16) evenly spacedacross the width of the base member (12), in a generally parallelrelationship to a second side of the base member and to one another,such that each second support arm (16) intersects each of the firstsupport arms (14) in a generally perpendicular relationship. While anymanner of securing known in the art can be used to secure the secondsupport arms (16) to the first support arms (14), FIG. 1 depicts each ofthe first support arms (14) having a plurality of grooves or notches(18) disposed therein, sized to receive one of the second support arms(16). Additionally, FIG. 1 depicts a plurality of bolts or rivets, ofwhich rivet (20) is labeled, that are usable to secure the secondsupport arms (16) to the first support arms (14). Though the size andshape of the second support arms (16) can vary, as described previously,in an embodiment of the invention, each of the second support arms (16)can have a length equal to the length of the base member (12), a widthof approximately one inch, and a height of approximately two inches.

While the first and second support arms (14, 16) can be formed from anygenerally rigid, durable material able to withstand the weight of one ormore oilfield tubulars, exposure to drilling mud and other fluids, andexposure to ambient weather or other environmental conditions, invarious embodiments of the invention, the support arms (14, 16) can beformed from materials similar to those from which the base member (12)is formed, including plastic materials similar to those used withinthread protectors and/or similar plugs or caps for oilfield tubulars.

The intersection between the first and second pluralities of supportarms (14, 16) defines a plurality of openings, of which opening (22) islabeled, through which fluid from one or more oilfield tubulars can passto contact the base member (12) below. While FIG. 1 depicts the firstand second pluralities of support arms (14, 16) disposed in a generallyperpendicular relationship to one another, defining generally square orrectangular openings (22), it should be noted that other intersectingarrangements are also usable. In various embodiments of the invention,the support arms (14, 16) can be shaped and/or arranged to definetriangular openings, round openings, and/or a honeycomb shape orstructure.

FIG. 1 also depicts a plurality of side openings, of which side opening(24) is labeled, defined at their upper and lower bounds by theoutermost second support arms (16) and the base member (12),respectively, and at their lateral bounds by adjacent first structuralarms (14). It should be noted that while FIG. 1 depicts six sideopenings (24), embodiments of the structural container or mat (10) caninclude single side opening for use as a drain hole or similar accessopening for capturing and/or removing fluid, cleaning the mat (10), orother similar undertakings.

Referring now to FIGS. 2A and 2B, a top view and a side view of the mat(10) of FIG. 1 are shown, respectively. The first plurality of supportarms (14) are visible secured to the base member (12), while the secondplurality of support arms (16) are shown secured to the first pluralityof support arms (14) in a generally perpendicular relationship using oneor more rivets (20) or similar fasteners. The plurality of openings (22)therethrough are thereby defined. FIG. 2B also depicts multiple sideopenings (24), as described previously.

Referring now to FIG. 3, an alternate embodiment of a structuralcontainer or mat (10) usable within the scope of the present disclosureis shown. In a similar manner to the embodiment shown in FIG. 1, thedepicted embodiment includes a base member (12) having a first pluralityof support arms (14) secured thereto, and a second plurality of supportarms (16) secured to the first plurality of support arms (14), using oneor more rivets (20) or similar fasteners. A plurality of openings (22)are thereby defined, through which fluid from one or more oilfieldtubulars can drain when the tubulars are placed above the support arms(14, 16) or within the openings (22), as described previously. FIG. 3also depicts one or more side openings (24), usable for emptying of themat (10), as described previously.

FIG. 3 further depicts a bounded region (26) having an open top, lackingsupport arms above. The bounded region (26) is enclosed from below by aportion of the base member (12), from two sides by the outermost of thefirst support arms (14), and from the side opposite the support arms(14, 16) by a back wall (28). The bounded region (26) is usable toreceive drilling mud or other fluids that have been pushed, rinsed, orotherwise moved from beneath the support arms (14, 16), enabling readyaccess to the fluid for vacuuming or other methods of removal and/orcollection due to the open top of the bounded region (26).

Referring now to FIGS. 4A and 4B, a top view and a side view of the mat(10) of FIG. 3 are shown, respectively. The first plurality of supportarms (14) are visible secured to the base member (12), while the secondplurality of support arms (16) are shown secured to the first pluralityof support arms (14) in a generally perpendicular relationship using oneor more rivets (20) or similar fasteners. The plurality of openings (22)therethrough are thereby defined. FIG. 2B also depicts multiple sideopenings (24), as described previously. The bounded region (26),enclosed by the outermost of the first support arms (14) and the backwall (28) is also depicted.

Embodiments of the present invention thereby provide methods andstructural containers or mats that support the weight of one or moreoilfield tubulars while receiving fluid that drains from the interior ofsuch tubulars, preventing the drained fluid from contacting a rig floorand creating a potentially hazardous situation, and/or a situation thatwill require significant remedial or clean-up operations. Collectedfluid can then be reclaimed or discarded.

While the present invention has been described with emphasis on certainembodiments, it should be understood that within the scope of theappended claims, the present invention can be practiced other than asspecifically described herein.

1. A mat for preventing fluid from one or more oilfield tubulars fromspreading on a rig floor, the mat comprising: a base member at leastpartially impermeable to fluid from the tubulars; a first plurality ofsupport arms secured to the top surface of the base member along a firstside and having a second side spaced from the first side; and a secondplurality of support arms intersecting at least one of the firstplurality of support arms to define a plurality of openings to allowmovement of fluid from the tubulars through the plurality of openings tothe base member, thereby preventing the fluid from spreading on the rigfloor.
 2. The mat of claim 1, wherein the first plurality of supportarms are generally parallel to a first side of the base member, andwherein the second plurality of support arms are generally parallel to asecond side of the base member.
 3. The mat of claim 1, wherein thesecond plurality of support arms intersect the first plurality ofsupport arms in a generally perpendicular relationship.
 4. The mat ofclaim 1, wherein the second plurality of support arms intersect thefirst plurality of support arms to provide at least one of the pluralityof openings with a square shape, a rectangular shape, a triangularshape, a round shape, a honeycomb shape, or combinations thereof.
 5. Themat of claim 1, wherein the base member comprises a bounded regionextending beyond the first plurality of support arms and the secondplurality of support arms, wherein the bounded region comprises an opentop for facilitating removal of fluid therefrom.
 6. A method forreceiving fluid from one or more oilfield tubulars, the methodcomprising the steps of: placing at least one oilfield tubularcontaining fluid on a mat adapted to receive the fluid, wherein the matis disposed over the rig floor, and wherein the mat supports a weight ofsaid at least one oilfield tubular; orienting said at least one oilfieldtubular in a position such that the fluid from said at least oneoilfield tubular flows toward the mat; and permitting the fluid to passthrough openings of the mat, wherein the mat prevents the fluid fromspreading on the rig floor.
 7. The method of claim 6, wherein the stepof placing said at least one oilfield tubular containing fluid on themat comprises placing said at least one oilfield tubular on a pluralityof support arms of the mat spaced apart from a base member of the mat,and wherein fluid that passes through the openings of the mat contactsthe base member and is prevented from spreading on the rig floor.
 8. Themethod of claim 6, wherein the step of placing said at least oneoilfield tubular containing fluid on the mat comprises placing an end ofsaid at least one oilfield tubular within at least one of the openings,wherein fluid that flows toward the mat contacts a base member of themat and is prevented from spreading on the rig floor.
 9. The method ofclaim 6, wherein the step of orienting said at least one oilfieldtubular in a position such that the fluid from said at least oneoilfield tubular will flow in a downward direction comprises placingsaid at least one oilfield tubular in a generally vertical orientation.10. The method of claim 6, wherein the step of permitting the fluid topass through the openings of the mat comprises permitting the fluid todrain from said at least one oilfield tubular to contact a base memberdisposed beneath the openings of the mat, wherein the base membercomprises a material at least partially impermeable to the fluid andprevents the fluid from spreading on the rig floor.
 11. The method ofclaim 6, further comprising the steps of moving the fluid to a boundedregion of the mat comprising an open top and removing the fluid throughthe open top of the bounded region.
 12. The method of claim 6, furthercomprising the step of placing the mat within a depression in the rigfloor such that a top surface of the mat is generally flush with the rigfloor.
 13. A mat for receiving fluid one or more oilfield tubularssupported thereon while at least partially supporting a weight of saidoilfield tubulars, the mat comprising: a base member having a topsurface comprising a material at least partially impermeable to thefluid from said oilfield tubulars; a plurality of first structural armssecured to the top surface of the base member, wherein the firstplurality of support members comprise a first height adapted to supportthe weight of said oilfield tubulars, and wherein the first plurality ofsupport members each comprise a plurality of notches formed therein; asecond plurality of structural arms secured to the plurality of firststructural arms, wherein the second plurality of support arms comprise asecond height adapted to support the weight of said oilfield tubulars,wherein the second plurality of structural arms are disposed within theplurality of notches of the first plurality of structural arms, andwherein the second plurality of structural arms are secured in agenerally perpendicular relationship with respect to the first pluralityof structural arms, thereby defining a plurality of openings forpermitting passage of fluid from said oilfield tubulars through theplurality of openings to contact the base member, thereby preventing thefluid from spreading on the rig floor.
 14. The mat of claim 13, furthercomprising at least one side opening for facilitating emptying of themat.
 15. The mat of claim 13, wherein the base member comprises abounded region extending beyond the first plurality of support arms andthe second plurality of support arms, wherein the bounded regioncomprises an open top for facilitating removal of fluid therefrom.